Fuel Pump: Service and Repair

WARNING: Do not smoke, carry lighted tobacco or open flame of any type when working on or near any fuel related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury.

CAUTION: Fuel supply lines will remain pressurized for long periods of time after engine shut down. This pressure must be relieved before servicing of the fuel system is begun. A valve is provided on the throttle body for this purpose. Remove the air cleaner and relieve system pressure by using Rotunda pressure gauge tool T80L-9974-A or equivalent and drain the system through the drain tube.

REMOVAL

1. Relieve the fuel system pressure.
2. Disconnect the negative battery cable.
3. Remove the rear seat cushion.
4. Disconnect fuel tank sending unit and pump electrical connector.
5. Remove the ground strap retaining screw and the three remaining fuel pump assembly cover screws.

Fuel Tank Sending Unit And Pump Assembly:

6. Remove the fuel pump assembly cover.

Fuel Tank Sending Unit And Pump Assembly:

7. Remove the clips from the fuel hoses.

Fuel Tank Sending Unit And Pump Assembly:

8. Disconnect the fuel hoses from the fuel pump assembly.

Fuel Pump Retainer:

9. Using a Fuel Tank Sender Wrench D84P-9275-A or equivalent, carefully remove fuel pump locking retainer ring.

Fuel Sender/Fuel Pump Assembly:

10. Remove the fuel pump assembly and discard the gasket.

INSTALLATION

1. Install a new fuel pump mounting gasket and position the fuel pump assembly in the fuel tank.
2. Install the fuel pump spanner nut.
3. Connect the fuel hoses to the fuel pump assembly.
4. Install the clips onto the fuel hoses.
5. Position the fuel pump assembly cover and ground strap and install the retaining screws.
6. Connect the fuel pump assembly electrical connector.
7. Install the rear seat cushion.
8. Connect the negative battery cable.
9. After replacing the fuel/pump sender, be sure to replenish the tank with fresh fuel.